Wiring device



June 9, 1959 c. M. SMITH 2,890,255

WIRING DEVICE Filed May 5, 1954 2 Sheets-Sheet 1 Fig.2.

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47; INVENTOR 45/ ATTORNEY Clarence M. Smith.

June 9, 1959 c. M. SMITH 2,890,265

WIRING DEVICE Filed May 5, 1954 2 Sheets-Sheet 2 Fig.7.

5 8 484648 56 *L $rtgiju JIOT WIRING DEVICE Clarence M. Smith, Bridgeport, Cnn., assignor to-The I Bryant Electric Company, Bridgeport, Conm, a cor- ,poration of Connecticut Application May 5, 1954, Serial No. 427,734

. 11 Claims. (Cl. 174-53) My invention relates, generally, to electric wiring devices and, more particularly, to a new and improved means for assembling such devices.

Although in principle my invention is applicable to a wide variety of wiring devices, it is more particularly suited for the smaller low voltage devices where the use ofstandard fastening means, such as screws, formed plates, spun bushings, rivets, etc., represents a substantial percentage of the cost of the complete wiring device. The above-mentioned types of fastening means have required both additional material and handling which have resulted in increased fabrication costs which, in some cases, far exceed the value of the added components of the device. As can be appreciated, such fabrication processes also require machinery and dies, whereby the processes can be formed on a production basis which is an additional expense and must be reflected in the selling price of the wiring device. Also, in such devices the use of standard fastening means has to some degree affected the appearance of the product adversely.

Accordingly, one object of my invention is to provide a new and improved wiring device of simplified construction.

Anotherobject of my invention is to provide a new and improved wiring device having a simplified fastening means which is inexpensive to produce.

A further object of my invention is to provide a new and improved wiring device having a minimum of component parts.

' Another object of my invention is to provide a new and improved wiring device having fastening means whereby the wiring device can be secured together in a single operation.

Another object of my device is to provide a new and improved wiring device having a fastening means which is provided with integral means for engaging all the housing components of the wiring device when the fastening means is deformed.

A more specific object of my invention is to provide a new and improved electrical wiring device having a yoke which is provided with integral fastening means for securing the device together in a novel manner.

Yet another object of my invention is to provide a new and improved wiring device, wherein the parts of the device are secured together by deforming a mounting yoke for the device.

. Anotherobject of my invention is to provide a new and improved wiring device, whereby the parts of the device can be secured together by deforming a yoke by integral means on the yoke engaging the housing components of the device.

These and other objects of my invention will become more apparent upon considerationof the following detailed description of a wiring device incorporating fastening means constructed in accordance with the principles of my invention when taken in connection with the attached drawings, in which:

Figure 1 is a longitudinal sectional view of the top I yoke member constructed in accordance with the prin-i ice housing of a duplex receptacle taken substantially along the line I-I of Fig. 6;

Fig. 2 is a longitudinal sectional view of the bottom housing of a duplex receptacle taken substantially along the line II--II of Fig. 8 and having located thereon a ciples of my invention; I Fig. 3 is a partial side elevational and partial central longitudinal sectional view of the top and bottom hous ings of a duplex receptacle which are secured together" by a yoke constructed in accordance with the principles of my invention;

Fig. 4 is a transverse sectional view of the assembled duplex receptacle shown in Fig. 3, taken substantially along the line IVIV ofFig. 3;

Fig. 5 is a partial exploded perspective view of one end of the top and bottom housing of a duplex receptacle and a yoke constructed in accordance with the principles of my invention;

Fig. 6 is a bottom plan view of the top housing of the receptacle shown in Fig. 1;

Fig. 7 is a top plan view of a yoke constructed in accordance with the principles of my invention;

Fig. 8 is a top plan view of the bottom housing of the receptacle shown in Fig. 2; and

Fig. 9 is a partial elevational and partial sectional View of one end of the receptacle shown in Fig. 3.

Although my invention is suitable for various types of wiring devices, for the purpose only of better understanding my invention, the following description and drawings are with relation to a duplex electrical receptacle having housing members secured together by a yoke constructed in accordance with the principles of my invention. It is to be realized, however, that the integral means on the yoke whereby the housing members of the receptacle are secured together could be used with other types of wiring devices, and that such integral securing means may be found on elements other than the particular yoke herein illustrated.

As is well known, electric outlet boxes and wiring devices -for installation within such outlet boxes for low voltage applications, such as household wiring, have become standardized so that the various makes of boxes and devices are interchangeable. One standard type of mounting comprises a yoke member which extends longitudinally beyond each end of the wiring device, whereby the wiring device may be secured to an outlet box by a fastening means securing the ends-of the yoke to the outlet box. The illustrative embodiment of my invention, comprises providing such a yoke member with integral means which are cooperable with integral means on separate parts of the wiring device, so that the yoke member also secures such parts of the wiring device together.

Basically, the receptacle shown in the drawings comprises an upper housing 2, a lower housing 4, a pair of electrical contacts 6, and a yoke 8 for securing all of said components together. Upper housing 2 is adapted to be assembled with respect to lower housing 4, so that a pair of longitudinally extending chambers 3 are formed in which the electrical contacts 6 may be located, and so that an overall unitary structure is obtained. Both the housings 2 and 4 are formed from any suitable insulating material, and are preferably formed of a molded insulating material which may readily be provided with the necessary guides, offsets, and projections hereinafter described. Electrical contacts 6 are formed from any suitable resilient electrical conducting material, such as brass, which may readily be formed in a manner hereinafter described, while yoke 8 is formed of any suit- I able material which has sufficient structural strength, such as sheet steel.

Referring to Figs. 1, 3, 4, 5, 6, and 9, it will be noted that the upper housing 2 is an irregularly formed memher having a pair of irregularly formed downwardly extending laterally spaced sides and a pair of upwardly offset, longitudinally spaced, approximately circular faces 12, in each of which is located a pair of spaced slots 14. Slots 14 are provided in order that the prongs of a male plug (not shown) may be inserted to engage the electrical contacts 6. In order to facilitate the insertion of a male plug, the faces 12 of the upper housing 2 are slightly dished inwardly and an integral divider 16 is provided across each face 12 between the slots 14. Divider 16 serves to provide additional insulation between the two slots 14 and to provide additional mechanical strength for the upper housing 2 in a manner hereinafter discussed.

As more clearly shown in Fig. 5, each end of upper housing 2 is provided with an integral arrangement which is cooperable with portions of the yoke 8 to hold the upper housing 2 securely assembled with relation to lower housing '4. Primarily, it will be noted that the external end of each end of upper housing 2 is provided with a vertically extending flat bottom slot 18 which is narrowed at its lower end, whereby a pair of opposed upper side walls 29 and a pair of opposed lower side walls 22 are provided. Each upper side wall 20 is offset laterally outwardly from lower side walls 22 and is connected to the lower side wall 22 immediately below by a flat transverse surface 24 which is at approximately right angles to both of the side walls 2t) and 22. As this description proceeds, however, it will become apparent that surface 24 need not necessarily be flat or at right angles to side walls 20 and 22, but may assume various shapes and be located at other angles relative thereto. Also, each end of the upper housing 2 may be flattened off as at 26, if desired.

Referring to Figs. 2, 3, 4, 5, 8, and 9, lower housing 4 comprises an approximately rectangular base 28 which is provided with upwardly extending side walls 30, which, in turn, are joined together at each end of base 28 by upwardly extending end walls 32. Adjacent the longitudinal center line of lower housing 4 but displaced laterally on opposite sides thereof, the external side of each end wall 32 is provided with an integral pair of outwardly and upwardly extended tapered braces 34, which terminate in integral laterally inwardly extending rectangular locking blocks 36 having an opening 39 therebetween. Braces 34 elevate the lower surfaces 38 of blocks 36 above the top surface 40 of end walls 32. It will be noted that the portion of each end wall 32 between braces 34 is ofifset inwardly toward the center of housing 4 in order to brace integral dividers 66, hereinafter discussed.

As more clearly shown in Fig. 4, the upper edges of side walls of lower housing 4 are adapted to engage the lower 'edges of side walls 10 of upper housing 2 when the receptacle is assembled. As shown in Fig. 6, the upper housing 2 is provided with integral rectangular recesses 42 in its under side to receive blocks 36 on the lower housing 4, whereby upper housing 2 and lower housing 4 are definitely positioned relative to eachother when assembled. The upper housing 2 and the lower housing 4 are each symmetrical with relation to both their longitudinal and lateral center lines, and it is apparent, therefore, that it is immaterial which ends of the two housings are engaged during assembly. When so assembled, an upper pair of spaced longitudinally extending surfaces 24 and a lower pair of spaced longitudinally extending surfaces 38 are provided at each end of the receptacle which are longitudinally displaced from each other.

As has been indicated, one of the purposes of my invention is to utilize the yoke 8, which is required, as previously indicated, for mounting the receptacle, to secure the upper housing 2 and lower housing 4 together. Referring to Figs. 2, 3, and 8, it will be noted that lower housing 4 is provided with an integral upwardly extending hollow rectangular post 44 which is symmetrically located with reference to the longitudinal and lateral center lines of lower housing 4, and which supports the central enlarged rectangular portion 46 of yoke 8. As shown in Figs. 2, 3, and 7, yoke 8 includes the central portion 46 which is provided with any suitable securing means, such as dished threaded projections 48, whereby a face plate (not shown) may be secured to the receptacle. Central portion 46 is also provided at each end with integral downwardly extending arms 50 which receive post 44 therebetween, and arms 50 are substantially reduced in width from the central portion 46. Each arm 50 terminates in an integral longitudinally extending arm 52 which is at approximately right angles to arm 50, and each of which engages the top surface 49 of the central portion of the endwa'll 32 toward which it extends between the braces 34. Each arm 52 terminates in a rectangular tab 54 which is wider than arm 2, and approximately the same width as center '46, whereby a pair of laterally spaced rectangular corners 56 are formed at the end of each arm 52 on each tab '54. Each tab 54, in turn, terminates in an upwardly extending connecting link 58 which is generally T-shaped, whereby a pair of laterally spaced rectangular corners 60 are formed. Each link 58 terminates in an outwardly extending anchoring tab 62, whereby yoke 8 may be secured to a suitable standard outlet box (not shown) by any suitable means. As shown, yoke 8 is provided with a hole 64 in each tab 62 for securing purposes; however, 'it is obvious that tab 62 may be provided with any of the variety of known formations for securing purposes. It is to be noted that the tabs 54 and the corners 60 constitute abutment means which cooperate with the parts of the housing to prevent separation thereof in a manner to be hereinafter described.

Referring again to Figs. 4, 5, and 8, it will be noted that lower housing 4 is provided with two pairs of longitudinal upwardly extending walls 66 interiorly thereof which are displaced laterally on opposite sides of the longitudinal center line of lower housing 4, and which extend from opposite sides of post 44 to end walls 32. Upper housing 2 is provided substantially on its longitudinal center line with a pair of spaced integral longitudinally elongated downwardly extending irregular shaped members 70, which when assembled with the lower housing 4 form with the walls 66 the longitudinally extending chambers 3 'at each side of the longitudinal center line of the receptacle. Within each chamber 3 a formed contact 6 is securely located. Each contact 6 comprises an approximate U-shaped base 76, having a pair of integral inwardly extending and convergent movable terminal jaws 78, an integral curved inwardly projecting prong engaging portion at each end located beneath prong openings 14 at one side, and an integral jaw releasing extension 88. The particular construction of electrical contact '6 does not form a part of this invention and is more clearly described and claimed in my copending application Serial No. 427,733, filed May 5, 1954 on a Wiring Device, and which has been assigned to the same assignee as this invention.

In assembling such an electrical receptacle, the electrical contacts 6 are'initially inserted in the bottom half of chamber 3 within lower housing 4 and the yoke 8 is placed upon the top of lower housing 4 so that central portion 46 is located on top of 'the post 44, and the extending arms 52 engage the top surface 40 of end walls 32 between the braces 34. It will particularly be noted that when the yoke 8 is so positioned (Fig. 2) the spaced corners 56 are located longitudinally beyond blocks 36. Thereafter, the upper housing 2 is placed on the lower housing 4, and it is provided with various integral means so as to position all of the components of'the receptacle with relation to each other. Primarily, it will be noted that upper housing 2 is provided with a central opening 90 which is symmetrically disposed along the longitudinal and lateral center line of upper housing 2 in order to receive the upper end of post 44, and the central portion 46 of the yoke 8 will be accessible from the outside of the receptacle, whereby a faceplate may be secured to the threaded parts 48 of central portion 46 of yoke 8. A pair of longitudinally spaced recesses 92 are provided in opening 90 at each end thereof in order to accommodate the downwardly extending arms 50 of yoke 8. Recesses 92 serve both to align .the yoke 8 with reference to post 44 and to prevent lateral movement of the arms 50. The under side of upper housing 2 is provided with a pair of laterally extending tapered projections 94.on each side of each center member 70. which engage the inner surface of the respective contacts 6 to locate each contact 6 within its chamber 3 against side walls and 30. Projections 94 prevent the contacts 6 from being laterally displaced when electrical conductors are inserted therein, as hereinafter described. Similarly, a pair of integral lateral projections 96 are provided on the lateral center line of upper housing 2 in order to support electrical contact 6 between projections 96 and the sides of the receptacle at approximately the mid-point of contacts 6. Center members 70 of upper housing 2 are also provided on the longitudinal center line of upper housing 2 with a pair of spacedv recesses 98 which are located beneath divider 16, and with a pair of indentations 100 at each of its ends for a purpose hereinafter described. It will particularly be noted that each center member 70 engages an extending arm 52 of yoke 8 at each side of openings 98 so that each arm 52 is held against the upper surface 40 of the end walls 32 of lower housing 4 between braces 34, and is also held against post 44.

As shown in Figs. 2, 3, 4, and 8, the lower housing 4 is provided with a pair of spaced openings 102 along its longitudinal center line in the base 28, through which a ram (not shown) may enter and engage the portion of an arm 52 opposite a recess 98. By applying force to such a ram, each arm 52 may be deformed by the ram into recesses 98 of upper housing 2, as shown in Fig. 3. As a consequence of such a deformation of each arm 52, the outer ends of the yoke 8 will be displaced longitudinal- 1y inwardly, whereby at each end of the receptacle the corners 56 of tab 54 are located beneath the surfaces 38 of blocks 36, and the corners 60 of tab 58 are located above the surfaces 24 of upper housing 2. Thus it will be seen that when each arm 52 is deformed, the yoke 8 automatically locks the upper housing 2 to the lower housing 4, as shown in Figs. 3 and 9, by engagement with surfaces 24 and 38, and that the deformed part of arm 52 is entirely enclosed within the receptacle. Such a receptacle cannot readily be disassembled by hand as the deformed 'portions'of arms 52 are not readily accessible from outside the receptacle. Thus each arm 52 locks one end of thereceptacle, and if it, is desired to lock each end simultaneously, each arm 52 need only be deformed simultaneously.

In order to establish electrical connection to the contacts 6, the housings 2 and 4 are each provided with a series of mating semi-circular openings 82, 83, and 84 along their longitudinal parting line so that when upper housing 2 and lower housing 4 are assembled, a series of circular openings are formed through which an electrical conductor may be inserted. As shown, each receptacle is provided with a series of six holes at each side through which various sizes of electrical conductors normally used in the ordinary housing two-wire system may be inserted. Such an electrical conductor is securely held both electrically and mechanically between jaws 78 of contact 6 when it is inserted within the receptacle. Base 28 of lower housing 4 is provided with a pair of longitudinally spaced openings 104 adjacent each side wall 30 which are located on each side of the lateral center line of the 6 lower housing 4 so that if it is desired to release a conductor which is held by the jaws 78, a suitable tool, such as a screwdriver, may be inserted from the underside of the lower housing 4 to engage contact extension 88. By applying a moderate force to extension 88, the jaws 78 may be caused to separate, whereby an inserted electrical conductor may easily be withdrawn from the receptacle.

From the description, it will be noted that a receptacle constructed in accordance with the principles of my invention utilizes the engagement of a formed yoke with cooperating surfaces on both the upper and lower housings of a receptacle when the yoke is deformed in order to hold the housings in assembled relation. Obviously, the relative vertical position of corners 56 and 60 on tabs 54 and 58, respectively, as well as the contour of tabs 54 and 58, may be varied with relation to the surfaces 24 and 38 on the upper housing 2 and blocks 36 of lower housing 4, respectively. It is equally obvious that the means whereby the yoks 8 is supported in the receptacle may be varied depending on the particular construction employed. Also, if desired, yoke 8 may be provided with an indented portion 101, as shown in Figs. 2 and 7, which portion extends diagonally between each pair of tabs 58 and 54 and faces the upper housing 4. When the yoke 8 is deformed, the indented portion 101 will be longitudinally displaced to engage the recesses at each end of the upper housing 4. By this means, the ends of yoke 8 may be laterally located with respect to the completed receptacle.

Having described a preferred embodiment of my invention in accordance with the patent statutes, it is desired that the invention be not limited to the specific construction illustrated, as it is apparent that many modifications in addition to those specifically indicated herein may be made without departing from the spirit and scope of my invention; Accordingly, it is desired that my invention be interpreted as broadly as possible, and that it be limited only as required by the prior art.

1 I claim as my invention:

1. The method of forming an electrical wiring device comprising locating a malleable member upon a base so that opposed ends of said malleable member extend beyond said base, enclosing said malleable member except said opposed ends within an upper housing and said base, deforming at least a part of said enclosed malleable member, guiding said malleable member so that each of said opposed ends thereof are displaced toward each other and into engagement with both said base and said upper housing and said wiring device is secured together.

2. The method of forming an electrical wiring device comprising locating a malleable member upon a base so that opposed ends of said malleable member extend beyond saidbase, enclosing said malleable member except said opposed ends. within an upper housing and said base, and deforming a plurality of parts of said enclosed malleable member, guiding said malleable member so that each of said opposed ends thereof are displaced toward each other and into engagement with both said base and said upper housing and said wiring device is secured together.

3. The method of forming an electrical receptacle comprising locating a malleable member upon a base so that opposed ends of said malleable member extend beyond said base, mounting a pair of electrically conducting members adapted to be energized and engaged on said base, enclosing said conducting members and said malleable member except said opposed ends within an upper housing and said base, and deforming at least a part of said enclosed malleable member, guiding said malleable member so that each of said opposed ends thereof are displaced toward each other and into engagement with both said base and said upper housing and all the parts of said receptacle are secured together.

4. The method of forming an electrical wiring device comprising locating a malleable member upon a base so that at least one end of said malleable member extends beyond one side of said 'base, enclosing said malleable member except said one end within an upper housing and said base with a portion of said malleable member spaced from said one end being secured against movement, and deforming at least a part of said enclosed malleable member, guiding said malleable member so that said one end thereof is displaced towards its other end and into engagement with both said base and said upper housing and said wiring device is secured together.

5. The method of forming an electrical receptacle comprising locating a malleable member upon a base so that at least one end of said malleable member extends beyond one side of said base, inserting a pair of electrically conducting members within said base, enclosing said conducting members and said malleable member except said one end within an upper housing and said base with a portion of said malleable member spaced from said one end being secured against movement, and deforming at least a portion of said enclosed malleable member, guiding said malleable member so that said one end thereof is displaced towards its other end into engagement with both said base and said upper housing and all components of said receptacle are secured together.

6. An electrical wiring device comprising, a split hollow casing, means for securing the parts of said casing together comprising, a locking member located between said casing parts and having opposite ends thereof extending to the exterior of said casing, at least one opening in the casing opposed to an intermediate deformed part of said locking member for the insertion of a tool to deform said intermediate part of the locking member laterally to vary the distance between the aforesaid opposite ends thereof, said casing having an enlarged space receiving said intermediate portion of the locking member to permit lateral deformation of the latter, the opposite ends of said locking member being formed with abutment means projecting at least at one side of said locking member in engagement with surfaces on both parts of said casing which extend inwardly from the ends thereof to prevent separation of said casing parts.

7. An electrical wiring device comprising, a split hollow casing, means for securing the parts of said casing together comprising, a locking member located between said casing parts and having opposite ends thereof extending to the exterior of said casing, at least one opening in the casing opposed to an intermediate deformed part of said locking member for the insertion of a tool to deform said intermediate part of the locking member laterally to vary the distance between the aforesaid opposite ends thereof, said casing having an enlarged space receiving said intermediate portion of the locking member to permit lateral deformation of the latter, the opposite ends of said locking member being formed with abutment means projecting from opposite sides of said locking member in engagement with surfaces on both parts of said casing which extend inwardly from the ends thereof to prevent separation of said casing parts.

8. An electrical wiring device comprising, a split hol-.

low casing, means for securing the parts of said casing together comprising, a locking member located between said casing parts and having opposite ends thereof extending to the exterior of said casing, at least one opening in the casing opposed to an intermediate deformed part of said locking member for the insertion of a tool to deform said intermediate part of the locking member laterally to vary the distance between the aforesaid opposite ends thereof, said casing having an enlarged space receiving said intermediate portion of the locking member to permit lateral deformation of the latter, the opposite ends of said locking member being formed with abutment means projecting at least at one side of said locking member and spaced laterally of said locking member and in engagement with surfaces on both parts of said casing which extend inwardly from the ends thereof to prevent separation of said casing parts.

9. An electrical wiring device comprising, a split hollow casing, means for securing the parts of said casing together comprising, a locking member located between said casing parts and having opposite ends thereof extending to the exterior of said casing, a plurality of spaced openings in the casing opposed to spaced intermediate deformed parts of said locking member for the insertion of a tool to deform said intermediate parts of the locking member laterally to vary the distance between the aforesaid opposite ends thereof, said casing having an enlarged space receiving said intermediate portions of the locking member to permit lateral deformation of the latter, the opposite ends of said locking member being formed with abutment means projecting at least at one side of said locking member in engagement with surfaces on both parts of said casing which extend inwardly from the ends thereof to prevent separation of said casing parts.

10. An electrical wiring device comprising, a split hollow casing, means for securing the parts of said casing together comprising, a locking member located between said casing parts and having opposite ends thereof extending to the exterior of said casing, said opposite ends of said locking member being formed with abutment means projecting at least at one sideof said locking member in engagement with surfaces on both parts of said casing which extend inwardly from the ends thereof to prevent separation of said casing parts.

11. An electrical wiring device comprising, a split hollow casing, means for securing the parts of said casing together comprising, a locking member located between said casing parts and having opposite ends thereof extending to the exterior of said casing, the opposite ends of said locking member having integral abutment means overlying opposed outwardly facing surfaces of the parts of said casing, respectively to secure the casing parts against separation.

References Cited in the file of this patent UNITED STATES PATENTS 1,264,578 Sweeney Apr. 30, 1918 1,805,797 Bates May 19, 1931 2,132,295 Hawkins Oct. 4, 1938 2,292,084 Pistey Aug. 4, 1942 2,579,841 Ludwig DEC. 25, 1951 

